Vehicular radar sensor module

Abstract

A method for joining a vehicular radar sensor housing includes obtaining a first portion of a vehicular radar sensor housing and a second portion of the vehicular radar sensor housing. The first portion of the vehicular radar sensor housing includes a plastic joining surface and the second portion of the vehicular radar sensor housing includes a metal joining surface. The plastic joining portion of the first portion of the vehicular radar sensor housing is juxtaposed with the metal joining surface of the second portion of the vehicular radar sensor housing. The metal joining surface is heated, and heat is transferred from the metal joining surface to the plastic joining surface. The heat at least partially melts the plastic joining surface to thermally join the plastic joining surface and the metal joining surface.

1 . A method for assembling a vehicular radar sensor housing, the method comprising:
 obtaining a first portion of a vehicular radar sensor housing, wherein the first portion of the vehicular radar sensor housing comprises a plastic interface;   obtaining a second portion of the vehicular radar sensor housing, wherein the second portion of the vehicular radar sensor housing comprises a metal interface;   juxtaposing the plastic interface of the first portion of the vehicular radar sensor housing and the metal interface of the second portion of the vehicular radar sensor housing; and   heating the metal interface, wherein heat is transferred from the metal interface to the plastic interface, and wherein the heat at least partially melts the plastic interface to thermally join the plastic interface and the metal interface.   
     
     
         2 . The method of  claim 1 , wherein heating the metal interface comprises generating eddy currents within the metal interface. 
     
     
         3 . The method of  claim 1 , wherein the vehicular radar sensor housing is not joined via any of the group consisting of (i) fasteners, (ii) adhesives, (iii) welding and (iv) clips. 
     
     
         4 . The method of  claim 1 , wherein the method further comprises, after heating the metal interface, cooling the vehicular radar sensor housing. 
     
     
         5 . The method of  claim 4 , wherein cooling the vehicular radar sensor housing comprises active cooling. 
     
     
         6 . The method of  claim 4 , wherein the method further comprises, after cooling the vehicular radar sensor housing, disposing the vehicular radar sensor housing at a vehicle. 
     
     
         7 . The method of  claim 1 , wherein the plastic interface and the metal interface are joined at an axial join interface. 
     
     
         8 . The method of  claim 1 , wherein the plastic interface and the metal interface are joined at an axial and radial join interface. 
     
     
         9 . The method of  claim 1 , wherein the vehicular radar sensor housing accommodates a printed circuit board (PCB). 
     
     
         10 . The method of  claim 9 , wherein the first portion of the vehicular radar sensor housing comprises a protrusion that extends through the PCB to the second portion of the vehicular radar sensor housing to secure the PCB in place within a cavity formed by the vehicular radar sensor housing. 
     
     
         11 . The method of  claim 10 , wherein the protrusion comprises the plastic interface. 
     
     
         12 . The method of  claim 10 , wherein the vehicular radar sensor housing houses an antenna, and wherein the protrusion extends through the antenna. 
     
     
         13 . A method for assembling a vehicular radar sensor housing, the method comprising:
 obtaining a portion of a vehicular radar sensor housing, wherein the portion of the vehicular radar sensor housing comprises a metal interface;   obtaining a printed circuit board (PCB);   obtaining an antenna, wherein the antenna comprises a protrusion, and wherein the protrusion comprises a plastic interface;   disposing the antenna such that (i) the protrusion extends through the PCB to the portion of the vehicular radar sensor housing to secure the PCB in place between the antenna and the portion of the vehicular radar sensor housing and (ii) the plastic interface of the antenna is in contact with the metal interface of the portion of the vehicular radar sensor housing; and   heating the metal interface, wherein heat is transferred from the metal interface to the plastic interface, and wherein the heat at least partially melts the plastic interface to thermally join the plastic interface and the metal interface.   
     
     
         14 . The method of  claim 13 , wherein heating the metal interface comprises generating eddy currents within the metal interface. 
     
     
         15 . The method of  claim 13 , wherein the vehicular radar sensor housing is not joined via any of the group consisting of (i) fasteners, (ii) adhesives, (iii) welding and (iv) clips. 
     
     
         16 . The method of  claim 13 , wherein the method further comprises, after heating the metal interface, cooling the vehicular radar sensor housing. 
     
     
         17 . The method of  claim 16 , wherein the method further comprises, after cooling the vehicular radar sensor housing, disposing the vehicular radar sensor housing at a vehicle. 
     
     
         18 . A method for assembling a vehicular radar sensor housing, the method comprising:
 obtaining a first portion of a vehicular radar sensor housing, wherein the first portion of the vehicular radar sensor housing comprises a protrusion, and wherein the protrusion comprises a plastic interface;   obtaining a second portion of the vehicular radar sensor housing, wherein the second portion of the vehicular radar sensor housing comprises a metal interface;   obtaining a printed circuit board (PCB);   obtaining an antenna;   disposing the antenna and the PCB within a cavity formed by the vehicular radar sensor housing such that (i) the protrusion extends through the antenna and the PCB to the second portion of the vehicular radar sensor housing and (ii) the plastic interface of the protrusion is in contact with the metal interface of the second portion of the vehicular radar sensor housing; and   heating the metal interface, wherein heat is transferred from the metal interface to the plastic interface, and wherein the heat at least partially melts the plastic interface to thermally join the plastic interface and the metal interface.   
     
     
         19 . The method of  claim 18 , wherein heating the metal interface comprises generating eddy currents within the metal interface. 
     
     
         20 . The method of  claim 18 , wherein the vehicular radar sensor housing is not joined via any of the group consisting of (i) fasteners, (ii) adhesives, (iii) welding and (iv) clips. 
     
     
         21 . The method of  claim 18 , wherein the method further comprises, after heating the metal interface, cooling the vehicular radar sensor housing. 
     
     
         22 . The method of  claim 21 , wherein the method further comprises, after cooling the vehicular radar sensor housing, disposing the vehicular radar sensor housing at a vehicle.